U.S. patent application number 12/484921 was filed with the patent office on 2010-12-16 for electric vehicle.
This patent application is currently assigned to Polaris Industries Inc.. Invention is credited to Stephen G. Crain, Josh J. Leonard, Joel M. Notaro, Russ G. Olsen, Dennis P. Sabourin, Kurt E. Stenberg.
Application Number | 20100314184 12/484921 |
Document ID | / |
Family ID | 43305451 |
Filed Date | 2010-12-16 |
United States Patent
Application |
20100314184 |
Kind Code |
A1 |
Stenberg; Kurt E. ; et
al. |
December 16, 2010 |
ELECTRIC VEHICLE
Abstract
A utility vehicle is disclosed having an electric drive. The
drivetrain is comprised of batteries, a motor, a transaxle driven
by the motor, a rear differential driven by the transaxle, and a
prop shaft which is driven by the transaxle and drives a front
differential. The batteries are provided in two groups and are
supported on the frame of the vehicle.
Inventors: |
Stenberg; Kurt E.;
(Greenbush, MN) ; Notaro; Joel M.; (North Branch,
MN) ; Leonard; Josh J.; (North Branch, MN) ;
Crain; Stephen G.; (Hudson, WI) ; Sabourin; Dennis
P.; (Roseau, MN) ; Olsen; Russ G.; (Taylors
Falls, MN) |
Correspondence
Address: |
Baker & Daniels LLP-Polaris
300 N. Meridian Street, Suite 2700
Indianapolis
IN
46204
US
|
Assignee: |
Polaris Industries Inc.
Medina
MN
|
Family ID: |
43305451 |
Appl. No.: |
12/484921 |
Filed: |
June 15, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61187147 |
Jun 15, 2009 |
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Current U.S.
Class: |
180/65.6 ;
180/65.1 |
Current CPC
Class: |
B60L 50/66 20190201;
Y02T 10/70 20130101; Y10T 477/3225 20150115; B60K 1/04 20130101;
B60L 58/21 20190201; B60L 2240/423 20130101; B60L 2260/28 20130101;
B60L 58/20 20190201; B60K 17/346 20130101; B60L 53/18 20190201;
B60L 2240/12 20130101; Y02T 10/62 20130101; Y10T 477/322 20150115;
Y10T 477/32 20150115; Y10T 477/30 20150115; Y02T 10/72 20130101;
Y02T 10/64 20130101; Y02T 90/12 20130101; Y02T 90/14 20130101; B60K
6/52 20130101; B60K 17/356 20130101; B60L 7/12 20130101; B60L
2210/12 20130101; B60L 2240/36 20130101; B60L 50/62 20190201; B60L
2240/425 20130101; B60L 2200/22 20130101; Y02T 10/7072
20130101 |
Class at
Publication: |
180/65.6 ;
180/65.1 |
International
Class: |
B60K 1/00 20060101
B60K001/00 |
Claims
1. An electric vehicle, comprising: a frame having first and second
ends and a seat supporting portion therebetween; a plurality of
ground engaging members supporting the frame; a plurality of
batteries supported by the frame intermediate the first and second
ends and divided into a plurality of groups of batteries leaving at
least one longitudinal opening therebetween; an electronic
controller mounted transversely in the longitudinal opening; a
first differential supported by the frame adjacent the first end; a
second differential supported by the frame adjacent the second end;
an electric motor supported by the frame adjacent the first end and
operatively connected to the first differential; and a prop shaft
operatively connected to the motor and extending through the
longitudinal opening and operatively connected to the second
differential.
2. The vehicle of claim 1, wherein the first end is a rear end of
the vehicle frame.
3. The vehicle of claim 1, further comprising a transaxle connected
to the motor having a rearwardly directed drive operatively
connected to the first differential and a forwardly directed drive
operatively connected to the prop shaft.
4. The vehicle of claim 1, wherein the frame is comprised of plural
longitudinally extending frame members and the seat supporting
portion is comprised of plural crossbars extending laterally
across, and elevated from, the frame members.
5. The vehicle of claim 4, wherein the electronic controller is
mounted to the crossbars and extending downwardly into the
longitudinal opening.
6. The vehicle of claim 5, wherein the groups of batteries are
connected to each other in parallel and the batteries within each
group are serially connected to each other.
7. The vehicle of claim 6, wherein the batteries are separated into
two groups of batteries and the longitudinal opening is positioned
generally centrally relative to the lateral width of the
vehicle.
8. The vehicle of claim 6, wherein the batteries are electrically
connected to the electronic controller.
9. The vehicle of claim 8, wherein all of the electrical
connections to and from the electronic controller are made to one
face of the electronic controller.
10. The vehicle of claim 4, wherein the batteries are positioned
within the seat supporting portion.
11. The vehicle of claim 10, further comprising a seat bottom
support positioned over the seat supporting portion and over the
batteries.
12. The vehicle of claim 11, wherein the seat bottom support is
profiled for riders in a side by side configuration.
13. The electric vehicle of claim 1, wherein the motor is an AC
motor.
14. An electric vehicle, comprising: a frame having a front end and
a rear end; a plurality of batteries supported by the frame; an
electric motor mounted adjacent a rear end of the frame; a rear
differential mounted adjacent a rear end of the frame and
operatively connected to the electric motor; and a front
differential and overrunning clutch operatively connected to the
electric motor.
15. The electric vehicle of claim 14, wherein the overrunning
clutch engages when the front differential slips by a predetermined
percentage.
16. The electric vehicle of claim 15, wherein the predetermined
percentage is between 10%-30%.
17. The electric vehicle of claim 14, wherein the motor is an AC
motor.
18. The electric vehicle of claim 14, wherein the plurality of
batteries are divided into two groups leaving a center longitudinal
opening therebetween.
19. The vehicle of claim 18, wherein the two groups of batteries
are connected to each other in parallel and the batteries within
each group are serially connected to each other.
20. The electric vehicle of claim 18, wherein each group of
batteries is comprised of four-twelve volt batteries.
21. An all wheel drive electric vehicle, comprising: a frame having
first and second ends; a plurality of ground engaging members
supporting the frame; first and second drive linkages positioned
proximate the first and second ends and operatively connected to
ground engaging members at the first and second ends; a motor
attached to the frame first end and operatively connected to the
first and second drive linkages; and a plurality of batteries
supported by the frame intermediate the first and second ends, the
batteries defining a plurality of groups of batteries electrically
connected in parallel and the individual batteries within each
group being electrically connected in series.
22. The electric vehicle of claim 21, wherein the motor is an AC
motor.
23. The electric vehicle of claim 21, wherein the plurality of
batteries is defined into two groups where each group of batteries
is comprised of four-twelve volt batteries.
24. The electric vehicle of claim 21, wherein the groups of
batteries define at least one center longitudinal opening
therebetween.
25. The electric vehicle of claim 24, further comprising an
electronic controller mounted in the center longitudinal
opening.
26. The vehicle of claim 21, wherein the frame is comprised of
plural longitudinally extending frame members and the seat
supporting portion is comprised of plural crossbars extending
laterally across, and elevated from, the frame members.
27. The electric vehicle of claim 26, wherein the frame further
comprises a support shelf positioned on the longitudinally
extending frame members, and the plurality of batteries are
supported by the support shelf.
28. The electric vehicle of claim 27, wherein further comprising a
seat bottom positioned over the plurality of batteries.
29. An electric vehicle, comprising: a frame having first and
second ends and a seat supporting portion therebetween; a plurality
of batteries supported by the frame intermediate the first and
second ends and divided into a plurality of groups of batteries
leaving at least one longitudinal opening therebetween; an
electronic controller supported by the frame and extending
transversely into the longitudinal opening; an electric motor
supported by the frame adjacent to the first end; and electrical
couplings, coupling the batteries to the electronic controller, and
the electronic controller to the motor, wherein all of the
electrical connections to and from the electronic controller are
made to one face of the electronic controller.
30. The electric vehicle of claim 29, wherein the first end is a
rear end of the vehicle frame.
31. The electric vehicle of claim 29, wherein the vehicle is an all
wheel drive vehicle having a first differential mounted adjacent
the first end and a second differential mounted adjacent the second
end.
32. The electric vehicle of claim 29, wherein the plurality of
batteries are divided into two groups leaving a center longitudinal
opening therebetween.
33. The electric vehicle of claim 32, wherein the two groups of
batteries are connected to each other in parallel and the batteries
within each group are serially connected to each other.
34. The electric vehicle of claim 29, wherein the batteries are
positioned within the seat supporting portion.
35. The electric vehicle of claim 34, wherein the frame is
comprised of plural longitudinally extending frame members and the
seat supporting portion is comprised of plural crossbars extending
laterally across, and elevated from, the frame members.
36. The electric vehicle of claim 35, wherein the frame further
comprises a support shelf positioned on the longitudinally
extending frame members, and the plurality of batteries are
supported by the support shelf.
37. The electric vehicle of claim 35, wherein the electronic
controller is supported by the crossbars and is positioned within
the center longitudinal opening.
38. The electric vehicle of claim 29, wherein the controller is
mounted to a support member which is attached to the frame.
39. The electric vehicle of claim 38, further comprising a
contactor, mounted to the support member adjacent to the
controller.
40. The electric vehicle of claim 39, wherein the contacts of the
contactor are oriented in the same direction as said one face of
controller.
41. An electric vehicle, comprising: a frame having first and
second ends; a seat supporting portion supported by the frame
having a front and rear end; a plurality of batteries supported by
the frame rearward of the seat supporting portion front end; an
electronic controller supported by the frame; an electric motor
supported by the frame adjacent the first end; at least one
charging unit supported by the frame forward of the seat supporting
portion front end; and electrical couplings, coupling the batteries
to the electronic controller, the electronic controller to the
motor, and the charging unit to the plurality of batteries.
42. The vehicle of claim 41, wherein the first end is a rear end of
the vehicle frame.
43. The vehicle of claim 42, wherein the vehicle is an all wheel
drive vehicle having a first differential mounted adjacent the
first end and a second differential mounted adjacent the second
end.
44. The vehicle of claim 41, wherein the batteries are positioned
within the seat supporting portion.
45. The electric vehicle of claim 44, wherein the plurality of
batteries are divided into two groups leaving a center longitudinal
opening therebetween.
46. The vehicle of claim 45, wherein the two groups of batteries
are connected to each other in parallel and the batteries within
each group are serially connected to each other.
47. The vehicle of claim 44 wherein the frame is comprised of
plural longitudinally extending frame members and the seat
supporting portion is comprised of plural crossbars extending
laterally across, and elevated from, the frame members.
48. The vehicle of claim 47, wherein the electronic controller is
mounted to the crossbars.
49. The vehicle of claim 47, wherein the frame further comprises a
support shelf positioned on the longitudinally extending frame
members, and the plurality of batteries are supported by the
support shelf.
50. An all wheel drive electric vehicle, comprising: a frame having
front and rear ends; a plurality of ground engaging members
supporting the frame; a front drive linkage supported by the frame
and positioned adjacent the frame front end; a rear drive linkage
supported by the frame and positioned adjacent the frame rear end;
a plurality of batteries supported by the frame; an AC electric
motor supported by the frame and mounted adjacent to the rear end,
the motor being operatively connected to the front and rear drive
linkages; an electronic controller; and electrical couplings,
coupling the batteries to the electronic controller and the
electronic controller to the motor.
51. The all wheel drive electric vehicle of claim 50, wherein the
front drive linkage is comprised of a front differential and an
overrunning clutch operatively connected to the motor.
52. The all wheel drive electric vehicle of claim 51, wherein the
overrunning clutch engages when the front differential slips by a
predetermined percentage.
53. The all wheel drive electric vehicle of claim 51, wherein the
predetermined percentage is between 10%-30%.
54. The all wheel drive electric vehicle of claim 50, wherein the
plurality of batteries are divided into two groups leaving a center
longitudinal opening therebetween.
55. The all wheel drive electric vehicle of claim 54, wherein the
two groups of batteries are connected to each other in parallel and
the batteries within each group are serially connected to each
other.
56. The all wheel drive electric vehicle of claim 55, wherein the
frame is comprised of plural longitudinally extending frame members
and the seat supporting portion is comprised of plural crossbars
extending laterally across, and elevated from, the frame
members.
57. The all wheel drive electric vehicle of claim 56, wherein the
electronic controller is mounted to the crossbars.
58. The all wheel drive electric vehicle of claim 57, wherein the
frame further comprises a support shelf positioned on the
longitudinally extending frame members, and the plurality of
batteries are supported by the support shelf.
59. The all wheel drive electric vehicle of claim 58, wherein
further comprising a seat bottom positioned over the plurality of
batteries.
60. The all wheel drive electric vehicle of claim 50, further
comprising at least one charging unit mounted adjacent to the front
end and electrical couplings, coupling the charging unit to the
plurality of batteries.
Description
RELATED APPLICATIONS
[0001] Reference is made to our co-pending, concurrently filed
provisional application, Ser. No. 61/187,147, docket
PLR-06-23794.02P, the subject matter of which is incorporated
herein by reference.
BACKGROUND
[0002] The present invention relates generally to a drive system
for a vehicle and in particular to an electric vehicle.
SUMMARY
[0003] The present disclosure relates to vehicles, including
utility vehicles. The present disclosure relates to utility
vehicles having an electric drive train, and more particularly to
battery operated four wheel drive vehicles.
[0004] In an exemplary embodiment of the present disclosure, a
utility vehicle is provided comprising a frame having first and
second ends and a seat supporting portion therebetween. A plurality
of ground engaging members support the frame. A plurality of
batteries are supported by the frame intermediate the first and
second ends and are divided into a plurality of groups of batteries
leaving at least one longitudinal opening therebetween. An
electronic controller is mounted transversely in the longitudinal
opening. A first differential is supported by the frame adjacent
the first end and a second differential supported by the frame
adjacent the second end. An electric motor is supported by the
frame adjacent the first end and operatively connected to the first
differential. A prop shaft is operatively connected to the motor
and extends through the longitudinal opening and is operatively
connected to the second differential.
[0005] In another exemplary embodiment of the present disclosure, a
utility vehicle is provided comprising a frame having a front end
and a rear end; a plurality of batteries supported by the frame; an
electric motor mounted adjacent a rear end of the frame; a rear
differential mounted adjacent a rear end of the frame and
operatively connected to the electric motor; and a front
differential and overrunning clutch operatively connected to the
electric motor.
[0006] In a further exemplary embodiment of the present disclosure,
a vehicle is provided comprising a frame having first and second
ends; a plurality of ground engaging members supporting the frame;
first and second drive linkages positioned proximate the first and
second ends and operatively connected to ground engaging members at
the first and second ends; a motor attached to the frame first end
and operatively connected to the first and second drive linkages;
and a plurality of batteries supported by the frame intermediate
the first and second ends, the batteries defining a plurality of
groups of batteries electrically connected in parallel and the
individual batteries within each group being electrically connected
in series.
[0007] In yet still another exemplary embodiment of the present
disclosure, a utility vehicle comprises a frame having first and
second ends and a seat supporting portion therebetween; a plurality
of batteries supported by the frame intermediate the first and
second ends and divided into a plurality of groups of batteries
leaving at least one longitudinal opening therebetween; an
electronic controller supported by the frame and extending
transversely into the longitudinal opening; an electric motor
supported by the frame adjacent to the first end; and electrical
couplings, coupling the batteries to the electronic controller, and
the electronic controller to the motor, wherein all of the
electrical connections to and from the electronic controller are
made to one face of the electronic controller.
[0008] In yet still a further exemplary embodiment of the present
disclosure, a utility vehicle is provided comprising a frame having
first and second ends; a seat supporting portion supported by the
frame having a front and rear end; a plurality of batteries
supported by the frame rearward of the seat supporting portion
front end; an electronic controller supported by the frame; an
electric motor supported by the frame adjacent the first end; at
least one charging unit supported by the frame forward of the seat
supporting portion front end; and electrical couplings, coupling
the batteries to the electronic controller, the electronic
controller to the motor, and the charging unit to the plurality of
batteries.
[0009] In yet another exemplary embodiment of the present
disclosure, a utility vehicle is provided comprising a frame having
front and rear ends; a plurality of ground engaging members
supporting the frame; a front drive linkage supported by the frame
and positioned adjacent the frame front end; a rear drive linkage
supported by the frame and positioned adjacent the frame rear end;
a plurality of batteries supported by the frame; an AC electric
motor supported by the frame and mounted adjacent to the rear end,
the motor being operatively connected to the front and rear drive
linkages; an electronic controller; and electrical couplings,
coupling the batteries to the electronic controller and the
electronic controller to the motor.
[0010] The above mentioned and other features of the invention, and
the manner of attaining them, will become more apparent and the
invention itself will be better understood by reference to the
following description of embodiments of the invention taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of an exemplary utility
vehicle;
[0012] FIG. 2 illustrates a left side view of the exemplary utility
vehicle of FIG. 1;
[0013] FIG. 3 illustrates a right side view of the exemplary
utility vehicle of FIG. 1;
[0014] FIG. 4 illustrates a top view of the exemplary utility
vehicle of FIG. 1;
[0015] FIG. 5 illustrates a top perspective view of the exemplary
utility vehicle of FIG. 1, with the body panels and roll-over
structure removed;
[0016] FIG. 5A illustrates an enlarged portion of the central part
of vehicle shown in FIG. 5;
[0017] FIG. 6 illustrates a bottom perspective view of the utility
vehicle as depicted in FIG. 5;
[0018] FIG. 6A illustrates an enlarged portion of the vehicle front
end shown in FIG. 6;
[0019] FIG. 6B illustrates an enlarged portion of the vehicle rear
end shown in FIG. 6;
[0020] FIG. 6C illustrates an enlarged portion of the vehicle
mid-section shown in FIG. 6;
[0021] FIG. 7 illustrates a top plan view of the electric
drivetrain of the utility vehicle of FIG. 1;
[0022] FIG. 8 illustrates a perspective view of the electric
drivetrain of the utility vehicle of FIG. 1;
[0023] FIG. 9 illustrates a front perspective view of a motor
controller of the utility vehicle of FIG. 1;
[0024] FIG. 10 shows a side view of the rear portion of the
drivetrain;
[0025] FIG. 10A illustrates a cross-sectional view taken through
lines 10A-10A of FIG. 10;
[0026] FIG. 11 illustrates a rear view of the rear frame and
drivetrain.
[0027] FIG. 12 illustrates a front perspective view of the front
frame and front portion of the drivetrain; and
[0028] FIG. 13 illustrates a cross-sectional view of the front
differential through lines 13-13 of FIG. 8.
DETAILED DESCRIPTION
[0029] Corresponding reference characters indicate corresponding
parts throughout the several views. Unless stated otherwise the
drawings are proportional.
[0030] The embodiments disclosed below are not intended to be
exhaustive or to limit the invention to the precise forms disclosed
in the following detailed description. Rather, the embodiments are
chosen and described so that others skilled in the art may utilize
their teachings. While the present disclosure is primarily directed
to a utility vehicle, it should be understood that the features
disclosed herein may have application to other types of vehicles
such as all-terrain vehicles, motorcycles, watercraft, snowmobiles,
and golf carts. Further, although described in the context of an
electric vehicle, the embodiments disclosed herein may be
implemented as part of a hybrid vehicle.
[0031] Referring to FIG. 1, an illustrative embodiment of a vehicle
100 is shown. Vehicle 100 as illustrated includes a plurality of
ground engaging members 102. Illustratively, ground engaging
members 102 are wheels 104 and associated tires 106. Other
exemplary ground engaging members include skis and tracks. In one
embodiment, one or more of the wheels may be replaced with tracks,
such as the Prospector II Tracks available from Polaris Industries,
Inc. located at 2100 Highway 55 in Medina, Minn. 55340.
[0032] In addition to vehicle 100, the teachings of the present
disclosure may be used in combination with the suspension systems,
drive configurations, modular sub-sections, and other features
described in any one of U.S. Provisional Patent Application Ser.
No. 60/918,502, titled VEHICLE, filed Mar. 16, 2007; U.S.
Provisional Patent Application Ser. No. 60/918,556, titled VEHICLE,
filed Mar. 16, 2007; U.S. Provisional Patent Application Ser. No.
60/918,444, titled VEHICLE WITH SPACE UTILIZATION, filed Mar. 16,
2007; U.S. Provisional Patent Application Ser. No. 60/918,356,
titled UTILITY VEHICLE HAVING MODULAR COMPONENTS, filed Mar. 16,
2007; U.S. Provisional Patent Application Ser. No. 60/918,500,
titled METHOD AND APPARATUS RELATED TO TRANSPORTABILITY OF A
VEHICLE, filed Mar. 16, 2007; U.S. Utility patent application Ser.
No. 12/050,048, titled VEHICLE WITH SPACE UTILIZATION, filed Mar.
17, 2008; U.S. Utility patent application Ser. No. 12/050,064,
titled VEHICLE WITH SPACE UTILIZATION, filed Mar. 17, 2008; U.S.
Utility patent application Ser. No. 12/050,041, titled METHOD AND
APPARATUS RELATED TO TRANSPORTABILITY OF A VEHICLE, filed Mar. 17,
2008; U.S. Utility patent application Ser. No. 12/092,151, titled
UTILITY VEHICLE HAVING MODULAR COMPONENTS, filed Apr. 30, 2008;
U.S. Utility patent application Ser. No. 12/092,153, titled
VEHICLE, filed Apr. 30, 2008; U.S. Utility patent application Ser.
No. 12/092,191, titled VEHICLE, filed Apr. 30, 2008, U.S. Utility
patent application Ser. No. 12/135,107, titled VEHICLE, filed Jun.
6, 2008, U.S. Utility patent application Ser. No. 12/134,909,
titled SUSPENSION SYSTEMS FOR A VEHICLE, filed Jun. 6, 2008, U.S.
Utility patent application Ser. No. 12/218,572, titled FLOORBOARD
FOR A VEHICLE, filed Jul. 16, 2008, and U.S. Utility patent
application Ser. No. 12/317,298, titled VEHICLE, filed Dec. 22,
2008, the disclosures of which are expressly incorporated by
reference herein.
[0033] Referring to the illustrated embodiment in FIG. 1, a first
set of wheels, one on each side of vehicle 100, generally
correspond to a front axle 108. A second set of wheels, one on each
side of vehicle 100, generally correspond to a rear axle 110.
Although each of front axle 108 and rear axle 110 are shown having
a single ground engaging members 102 on each side, multiple ground
engaging members 102 may be included on each side of the respective
front axle 108 and rear axle 110. As configured in FIG. 1, vehicle
100 is a four wheel, two axle vehicle. As mentioned herein one or
more of ground engaging members 102 are operatively coupled to a
drivetrain 112 (see FIGS. 7 and 8) to power the movement of vehicle
100, as further described herein.
[0034] Returning to FIG. 1, vehicle 100 includes a bed 120 having a
cargo carrying surface 122. Cargo carrying surface 122 may be flat,
contoured, and/or comprised of several sections. Bed 120 further
includes a plurality of mounts 124 for receiving an expansion
retainer (not shown) which may couple various accessories to bed
120. Additional details of such mounts and expansion retainers are
provided in U.S. Pat. No. 7,055,454, to Whiting et al., filed Jul.
13, 2004, titled "Vehicle Expansion Retainers," the disclosure of
which is expressly incorporated by reference herein. Further
reference is made to our pending applications Ser. No. 12/135,107
filed Jun. 6, 2008, entitled "VEHICLE"; Ser. No. 12/134,909 filed
Jun. 6, 2008, entitled "SUSPENSION SYSTEMS FOR A VEHICLE" and Ser.
No. 12/317,298 filed Dec. 22, 2008, entitled "VEHICLE", the
disclosures of which are expressly incorporated by reference
herein. Further reference is made to our co-pending, concurrently
filed provisional application, Ser. No. 62/______, the subject
matter of which is incorporated herein by reference.
[0035] Vehicle 100 includes an operator area 130 including seating
132 for one or more passengers. Operator area 130 further includes
a plurality of operator controls 134 by which an operator may
provide input into the control of vehicle 100. Controls 134 may
include controls for steering, acceleration and braking. As shown
in FIGS. 2 and 3, seating 132 includes a seat bottom portion 136
and a seat back portion 138 and head rests 140. Seating 132 is
shown in the present embodiment, as a split bench with the operator
side being adjustable along the longitudinal axis of vehicle 100.
As shown herein, the operator area 130 only shows a single bench
seat 132, but it should be appreciated that multiple tandem seats
could be incorporated.
[0036] Vehicle 100 includes four wheel independent suspensions.
Referring to FIG. 1, each of ground engaging members 102 of rear
axle 110 is coupled to frame 150 (FIG. 2) through a rear suspension
152. Rear suspension 152 includes double A-arms 154 and a shock 156
(FIG. 2). Each of ground engaging members 102 of front axle 108 is
coupled to frame 150 through front suspensions 160. Front
suspension 160 includes double A-arms 162 and a shock 164 (FIG.
1).
[0037] In addition to the bed 120, utility vehicle includes a
plurality of body components, and as best shown in FIGS. 2-4,
namely side panels 170, floor boards 172, wheel wells 174, dash
176, rollover structure 178, hood 180, and bumper 182. All of these
items are directly or indirectly attached to and/or supported by
the vehicle frame 150.
[0038] With reference now to FIGS. 5, 5A and 6, vehicle 100 is
shown with the body accessory parts and rollover structure 178
removed showing basically the frame 150 and drivetrain 112. As
shown best in FIG. 5, the vehicle has a front end 200, a rear end
202 and an intermediate portion 204 between the front and rear
portion 200, 202. Frame 150 includes corresponding front frame
portion 210, rear frame portion 212 and intermediate frame portion
214. The frame portions 210, 212, 214 provide support to drivetrain
112 as further described herein. In addition, frame 150 includes a
seat support portion 216 and a bed support portion 218.
[0039] With respect to FIGS. 6, and 6A-6C, frame 150 will be
described. Frame 150 includes longitudinally extending frame
members 220 which extend a substantial length of the vehicle and
neck down to form front frame members at 222. As shown best in FIG.
6A, support plates 224 and 226 span the frame members 222 for
support as described herein. As shown best in FIG. 6B, rear frame
portion 212 is defined by channel members 230 extending from a
transverse portion 232 which, in turn, extends between
longitudinally extending frame members 220. Plate portion 234
extends across channel members 230 to provide support for a rear
portion of the drivetrain 112, as described herein.
[0040] As best shown in FIG. 6C, intermediate frame portion 214 is
comprised of transverse channels 240 extending between
longitudinally extending frame members 220 and transverse channel
portions 242 and 244 extending outwardly from longitudinally
extending frame members 220. Two longitudinally extending straps
250 extend over one of the transverse channels 240 and over channel
232 defining a longitudinal opening 256 therebetween. The
longitudinal opening 256 is positioned generally centrally relative
to the lateral width of the vehicle. Frame tube 262 is positioned
at the end of transverse channel portions 242 and frame tube 264 is
positioned at the end of transverse channel portions 244. A support
platform 270 is positioned over channel 250, over at least two of
the transverse channel portions 242 and frame tube 262 and a
support platform 272 is positioned over the other of the frame
members 250 over at least two of the transverse channel portions
244 and over frame tube 264.
[0041] With respect again to FIG. 5A, seat support platform 216 is
comprised of crossbars 280, 282 which are elevated from the
longitudinal extending support members 220 by way of vertical
support members 284. As shown, cross bar 280 defines a front end of
the seat supporting portion.
[0042] With reference now to FIG. 7, drivetrain 112 is generally
comprised of rear drive 300, front drive 302, battery packs 304, a
prop shaft 306 interconnecting the rear and front drives 300, 302,
and a controller to control the motor speed and other electrical
functions. One or more chargers 310 are also provided to recharge
the batteries when the vehicle is idle. As also shown, battery
packs 304 comprise individual batteries 318 positioned rearward of
the front end of the seat supporting portion, and the chargers 310
are positioned forward of the front end of the seat supporting
portion.
[0043] With respect first to battery packs 304, two groups of
batteries 304A and 304B are defined where each battery group 304A,
304B includes a battery 318 of 12V capacity where each of the
groups 304A, 304B are wired in series, thereby defining two 48V
groups. Each of the groups 304A, 304B are connected through the
controller 308 in parallel to define a 48V power source. It should
be appreciated that battery group 304B is supported by platform 270
(FIG. 5) whereas battery group 304A is supported by platform 272
(FIG. 6C). With reference to FIGS. 6C and 7, each of the groups of
batteries 304A, 304B are also defined so as to flank longitudinal
opening 256 to provide room for prop shaft 306 extending
therethrough. As shown best in FIG. 7, battery group 304A is
serially connected by way of jumper cables 320, batteries in
battery group 304B are serially connected by way of jumper cables
322 and battery groups 304A and 304B are connected in parallel by
way of battery cables 324. In one embodiment, jumper cables 320 and
jumper cables 322 are the same length. As such, only two lengths of
battery cable are needed to connect all of the batteries of 304A
and 304B together.
[0044] With reference now to FIGS. 7-9, controller 308 and
contactor 330 are shown in greater detail. As shown best in FIG. 9,
both the controller and contactor are mounted on a support member
340 having an upper flange 342, a plate portion 344 and an end
flange 346. As shown, controller 308 can be mounted to plate
portion 344 with contactor 330 mounted to end flange 346. Top
flange 342 can be used to mount the controller and contactor 330
intermediate the battery groups 304A, 304B into the longitudinal
spacing 256 such that top flange 342 is arranged to span and attach
to crossbars 280, 282 (FIG. 5A). As also shown, contactor 330 is
oriented along a horizontal axis, with its contacts 332 projecting
in the same direction as connections for controller 308. This
allows all of the electrical connections to be made from the same
plane of the controller 330, as well as allows the movements of the
contactor relay to be along a horizontal plane, unaffected by road
vibration. As depicted, contactor 330 is a sealed contactor.
[0045] As mentioned above, the groups of batteries 304A, 304B input
to contactor 330 and to controller 308 as a source of power to
drivetrain 112. In the embodiment described, controller 308 is
manufactured by Sevcon, Inc. of Southborough, Mass. 01772, and is a
Series G48 AC motor controller, Model G4865. As shown best in FIG.
9, controller 308 has three AC motor outputs 350 and an I/O
connection port at 352. It should be appreciated from viewing FIG.
9, that all of the main electrical connections to the controller
308 and contactor 330 are centrally located, and are made to one
face, that is the side face as viewed in FIG. 9. In one embodiment,
a heat sink is mounted to controller 308 on the side opposite from
outputs 350.
[0046] With reference now to FIGS. 7, 10 and 11, rear drivetrain
portion 300 is generally comprised of an AC asynchronous motor 370
(or AC induction), a transaxle 372 which in turn drives
differential output 374 of differential 376 and forward drive shaft
378 which drives prop shaft 306 through universal joint 380 (FIG.
10). In the embodiment shown, motor 370 is manufactured by ABM
Greiffenberger Antriebstechnik GmbH, of Marktredwitz, Germany model
number 112-200-4. As shown best in FIG. 10A, transaxle 372
comprises an input from motor 370 to drive gear 382, which in turn
drives idler 384. Idler 384 drives pinion 386 which is connected to
reduction gear 388 which drives pinion 390. Pinion 390 drives the
differential which drives differential output 374 (FIG. 10), and
drives the forward drive shaft 378 (FIG. 10).
[0047] With respect now to FIGS. 8, 12 and 13, the front drivetrain
portion 302 will be described in greater detail. As shown in FIGS.
8 and 12, front drivetrain portion 302 includes a front
differential 400 interconnected to prop shaft 306 by way of a
universal joint 402. Differential 400 has two outputs 404 each of
which connect to one of the front wheels by way of drive shafts. As
shown, differential 400 is an automatic locking front differential
manufactured by Hilliard Corporation of Elmira, N.Y., and has an
overrunning clutch and as shown in FIG. 13, includes roller
bearings 408. Differential 400 also operates under the principle
described in U.S. Pat. No. 5,036,939, the subject matter of which
is incorporated herein by reference. Another overrunning clutch is
shown in U.S. Pat. RE38,012E, the subject matter of which is
incorporated herein by reference. As shown best in FIG. 13,
differential 400 has a differential gear 402 which is
engaged/disengaged by a plurality of roller bearings 404, during
wheel slippage, which in turn drives differential outputs 406, to
power the front wheels. Differential 400 is designed to engage when
the wheel slippage is in the range of 10-30%.
[0048] As mentioned above, battery groups 304A, 304B, power
contactor 330 and controller 308 (FIG. 7) are all positioned under
seat support. The speed of the vehicle 100 is controlled by a
signal pickup carried through cable 430 and interconnected to I/O
connector port 352 (FIG. 9) which in turn provides AC power to
motor 370 via cable 432 (FIGS. 7, 8) interconnected between three
phase ports 350 and motor 370. As mentioned above, one or more
chargers 310 are positioned in the front portion of the vehicle 100
and recharge battery groups 304A, 304B.
[0049] While this invention has been described as having an
exemplary design, the present invention may be further modified
within the spirit and scope of this disclosure. The application is,
therefore, intended to cover any variations, uses, or adaptations
of the invention using its general principles. Further, this
application is intended to cover such departures from the present
disclosure as come within known or customary practice in the art to
which this invention pertains.
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